Partially Remove Rear Longitudinal Member - Ar64.20-P-1260-01LW

	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	See AS00.00-Z-0010-01A .
	Risk of explosion  from aluminum grinding dust, risk of injury to respiratory system from inhaling dust	Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system.	See AS60.00-Z-0007-01N .
	Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	See AS00.00-Z-0002-01A .
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	See AS00.00-Z-0017-01A .
	General information on body repair		See AH60.00-N-0001-01A .
	Information on preventing damage to electronic components due to electrostatic discharge		See AH54.00-P-0001-01A .
	Pretreatment of bonding surfaces		See AH60.00-P-0008-01SX .
	General information on crack diagnosis of aluminum parts		See AH60.00-P-0014-01N .
	Note on working on aluminum components and vehicles		See AH60.00-P-0034-01LW .

Model 205 

Model 238 

The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

The following repair materials must be used:

• Zinc dust paint

1. Expose spot welds on rear-end floor (1) and cut out (areas A and B).

   Cut out spot welds through two sheet metal thicknesses (area B).

2. Expose self-piercing riveting on rear-end floor (1) with Ø 6 mm bit (areas C).
3. Expose impact spikes on rear-end floor (1) and cut out (area J).
   Fig 1: Rear-End Floor And Impact Spike Locations

   Courtesy of MERCEDES-BENZ USA
4. Expose spot welds on rear-end floor (1) and rear longitudinal member (2) and cut out (areas D).
5. Expose self-piercing riveting on rear longitudinal member (2) and drill with Ø 6 mm (area E).
6. Expose impact spikes on rear longitudinal member (2) and cut out (area H).
   Fig 2: Rear-End Floor, Rear Longitudinal Member And Impact Spike Locations

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

7. Heat rear-end floor (1) and rear longitudinal member (2) in cross-hatched areas.

   Cross-hatched areas are bonded with adhesive.

8. Remove rear-end floor (1) with rear longitudinal member (2).

   Courtesy of MERCEDES-BENZ USA

9. Grind mating surfaces down to bare metal in cross-hatched areas.

   Grind mating surfaces down to bare metal on inside (area F).

   Sand down spot weld flanges to bare metal on both sides.

10. Remove grinding dust and drill chips.
11. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas G and F).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.